Whether
you are a seasoned and experienced restorer, or new to the old truck restoration
hobby, you should always practice safety in the shop. The following
story and safety primer should help the novice as well as the expert remember
that safety is Job 1 in the shop -- always!

A
true story

Not
all old truck stories have happy endings...

A difficult story
to tell, by Barry Weeks.

"We
have all tried to forget about this, but we remember it everyday. 'Jonesey'
was a great guy who lived on a small 40-acre hobby farm. He and his wife were
fixing up the old farmhouse and barn. They gave the place a name: Dunmovin'
Acres. It was their dream place, and they were done moving. She had horses
and boarded a few. He had his old trucks and tractors and room for them. He
was a draftsman/designer at a tool & die company, was very talented and could
do most anything.

"One
Thursday night afterwork, I was rushing to load the truck so we could go out
of town. The whole Jonesey family (Dad, mom, son and daughter) came through
the gas station across the street from our house. Jonesey stopped in front
of my driveway and was waving: 'Hey,come here, I gotta tell you about something.'
I waved him off. 'No, I'm too busy to BS now, I'll stop over after the week-end,'
I told him.

"I
never saw him alive again.

"That
Saturday, he decided work on his old truck (a '49 Ford 1/2-ton). He was taking
the carb. or fuel pump off and gas started leaking in the garage. He pushed
the truck back out of the garage onto the apron, but it must've started rolling
down the driveway and he ran around the front to stop it. He left skid marks
in the dirt where he tried to stop it. It finally stopped when it hit a fence
post where the driveway curved. He was between the truck and the post. His
4-yr. old daughter was home with daddy and was able to make the 911 call,
'Please help my daddy.'

"The
authorities found his wife out on her rural mail route and got her to the
hospital just before he died of massive internal injuries. The funeral was
not fun. I think he was only about 31 at the time.

"Hardly
a day goes by that I don't wish I would've taken the time to talk to Jonesey
that Thursday night I saw him last. We were just getting to be buddies. I
did see his son at a swap meet this fall. He is now 16, and has his driver's
license. Seemed like he is a real decent person, just like his dad was. I
would guess that someday when his Mom sees fit, he will be given his dad's
old Ford pick-up. I hope he enjoys it as much as his dad did, but safely."

Thank you, Barry

A Shop Safety Primer

We
all know that working on our old trucks is dangerous! But sometimes,
either through lack of knowledge or complacency, that danger can rise up and
strike even the most competant and skilled restorer. Living to enjoy our finished
work demands safety awareness, common sense and care.
For your own safety, as well as that of those around you, please read these
safety tips and be familiar with the safe operation of the equipment in your
shop and its proper use when working on your vehicle. Even if you're an old
shop vet, re-reading safety tips can keep you from the clutches of complacency

Every year, people die
while working on their vehicles and more are injured. Almost without exception
such accidents are due to human error.

The three commonly observed
factors contributing to these deaths and injuries are:

Lack of knowledge

Inattention or distraction

Violation of safe
practices.

Serious hazards include dropping heavy components, improperly
secured loads, and incorrect use of equipment and tools.

Before
you start...

The best safety practice
you can do is to use your head and the common sense God gave each of us.
A good rule to follow is this -- if you think something might be unsafe, it
probably is. If it moves and can hurt you, make sure it's unplugged, shut
off, and locked out. Remove a battery cable before climbing in: electric fans
can start without the engine running, kids playing around in the cab can hit
the starter, etc...

Have a first aid kit readily
accessable as well. These days, we have cell and cordless phones available
-- use 'em! They can be your best safety tools and should be within reach
to dial 911 if you must work alone. When working alone, be sure you can be
seen from the street, if in the 'burbs. Some folks will not have this luxury
and for them, a phone nearby should be a must have.

Good
Work Habits

Keeping your area neat
and clean can help prevent accidents. When you are done with a tool, put it
away. Grease, oil, water and other liquids spilled on the floor cause serious
slipping hazards. Clean up spills immediately. For grease and oil spills,
use a non-combustible absorbent material. Put oily rags in a self-closing
container marked "Oily Rags Only."

To avoid tripping hazards
and cuts and bruises, keep your work area, aisles and walkways clear of parts,
tools and equipment. Parts, wrenches and other tools laying around the work
area are accidents waiting to happen.

You should not smoke within
50 yards of flammable materials. Thus, you should not smoke in your shop or
around your work area. Of course, you shouldn't smoke at all ...

Keep to a reasonable work
schedule. A lot of us work on our old vehicles after a long day at work. It
can be a real temptation to try and do too much each evening or Saturday morning
-- Don't! Don't work when you are tired or taking medication that could make
you drowsy. Work slowly and methodically -- don't rush your work! When you
get tired or frustrated, put the tools away, clean up your work area and quit
for the night because at that point, you are an accident about to happen.

And of course, alcohol
and grease don't mix -- save happy hour until after the work is done for the
day.

Fire
Extinguishers

A properly maintained fire
extinguisher is a mandatory item for any shop. If you have a larger shop,
you should have as many fire extinguishers as you need so that you can always
grab one quickly anywhere in the shop. Only use a Federally approved A-B-C
type fire extinuisher and be sure you know how to use it. If you use a Halon
extinguisher, remember that in an exclosed area, Halon will kill you the same
way it kills the fire -- by depriving you of oxygen very quickly. You should
not use Halon in an enclosed space. When using Halon on a fire, leave the
area immediately!

Lighting

Be sure your work area
is adequately lighted. When using a drop or shop light, be sure it is impact
resistant and in good operating condition.

Clothing
& Jewelery

You should always dress
appropriately for the work you are doing. If you wear long hair or loose clothing,
tie it back and secure it so it doesn't get caught up in something. Remove
rings, watches, chains, etc, that could get caught in rotating or closing
equipment (and thus remove fingers, hands or heads!). Loose long sleeves,
loose clothing or long hair (tie it back) should not be worn around rotating
equipment (PTO shafts, drill presses, grinders, engines, etc.) It will pull
you in a lot quicker than you can react. Forget the "Mr. T" routine,
chains are for the disco or hauling logs and binding loads -- they do not
belong around your neck in the shop.

Eye
and Hearing protection

Vision -- Wear safety glasses that comply with ANSI Z87-1 whenever
you are grinding, sanding, sand blasting, using a tool for striking
or engaged in any activity that can send something through your eyeball.
Everyday eye glasses only have impact resistant lenses; they are not
safety glasses. freakin54 shares this: "It is one I will never
forget . A coworker came to me with a wire from the wire wheel sticking
in the center of his eye, The eye was saved and no one in that shop
has ever forgotten!"

Hearing -- Use hearing protection when working around noisey
equipment or operations. Some hazards in the shop area which can cause
harmful noise levels include chipping, shearing, mechanical cutting,
hammering, grinding and sanding. Noise is the leading cause of hearing
loss in the U.S. Military with up to 50 percent of all personnel developing
significant hearing loss. When using equipment or conducting operations
designated as noise hazardous, be sure to wear hearing protection.

Respiratory -- Be sure to use breathing protection,
such as a respirator or dust mask, as appropriate. A filtration respirator
must be used when painting. Remember that some popular rust treatments,
like POR-15, when sprayed, can react to the moisture inside your lungs
and will bond there just like it does on your truck. And that makes breathing
rather difficult...

Hand
Tools

Most hand and power tools
can be dangerous if they are not operated in the right way or are used for
a purpose different than intended. Nationally, hand tools cause approximately
six percent of all compensable disabling injuries. Disabilities resulting
from misuse of tools or using damaged tools include loss of vision, puncture
wounds from flying chips, severed fingers, broken bones and contusions. Safety
precautions must be observed to prevent serious mishaps.

Learn each tool's application
and limitations, as well as the specific hazards peculiar to it. Keep all
guards in place and in good working order. Form a habit of checking to see
that keys and adjusting wrenches are removed from tool before turning it "on."

Before using, check wrenches
for cracks and worn jaws; screwdrivers for broken or rounded tips; hammers
for chipped, mushroomed, or loose heads and broken handles; chisels for mushroomed
heads; and extension cords or electric tools for broken plugs and frayed insulation.
If you find any of these defects, fix or replace the tool before using.

Don't force any tool --
It will do the job better and be safer to use at the rate for which it was
designed. Use the correct tool for the application -- Don't force a tool or
attachment to do a job for which it was not designed. Screwdrivers are not
chisels.

Don't use power tools in
damp or wet locations. To prevent electrical shocks, check your tools for
an intact ground wire prong or make sure they are double-insulated and don't
have frayed or worn cords. If tool is equipped with three-prong plug, it should
be plugged into a three-hole electrical receptacle. If an adapter is used
to accommodate a two-prong receptacle, the adapter lug must be attached to
a known ground. Never remove the third prong. If the third prong has been
cut off or the cord is frayed or cut, don't use the tool.

NEVER "rest" your tools
inside the engine compartment or at least count them in and count them out.

Secure your work. Use clamps
or a vise to hold work when practical. It's safer than using your hand and
frees both hands to operate the tool.

Stationary
Power Tools

Moving machine parts have
the potential for causing severe workplace injuries, such as crushed fingers
or hands, amputations, burns, and blindness, just to name a few. Safeguards
are essential for protecting workers from these needless and preventable injuries.
Machine guarding and related machinery violations continuously rank among
the top 10 of OSHA citations issued. In fact, "Mechanical Power Transmission"
(1910.219) and "Machine Guarding: General Requirements" (1910.212) were the
No. 6 and No. 7 top OSHA violations for FY 1997, with 3,077 and 3,050 federal
citations issued, respectively.

Electricity

NEVER work with equipment,
appliances, etc. when frayed, pinched, bare wires, loose connections, loose
or missing strain reliefs, damaged or poorly wired plugs or any signs of defects
are present. Regarless of age of electrical equipment. Always inspect the
appliance/tool for such obseverations. If you are not sure how to make repairs
on such items, DO NOT ATTEMPT to repair them. Tool and appliance repairmen
are out there and need the work. Give it to them. DO NOT Work with electricity
when it is raining, or wet in your work area. Wear insulating shoes and gloves.
If you haven't already converted to Ground Fault Interruption outlets in your
work shop, you should. But don't trust them 100 percent -- they're no substitute
for keeping your equipment in good condition. Also, Arc Fault detecting circuit
breakers are also becoming more available for residential and commercial use
(In fact, they will soon become mandatory per the National Building Code).

Compressed
Air

Inspect compressed air
hoses before using and replace cracked, worn or frayed hose. Reduce compressed
air below 30 psi for cleaning dirt and dust from parts and the work area and
never use compressed air to clean yourself or your clothes. Air must be shut
off and all pressure in the line must be released before disconnecting the
air hose from the air line.

Grinders

Grinders in the shop are
guarded to prevent injury if the grinding wheel breaks. Bench and pedestal
grinders have safety guards which cover at least three-fourths of the outside
of the wheel. The adjustable work or tool rest is required to be kept within
one-eighth inch of the wheel. The tongue guard must be kept within one-fourth
inch of the wheel. Make sure you only use the surface area of the wheel intended
for grinding and that all guards are in place. Wear all personal protective
equipment posted for the equipment.

Hydraulic
Lifts

You need to take certain
precautions when operating a hydraulic lift. Review the lift's instructions
prior to operating it. Be sure you understand them. Make sure everyone is
standing clear of the vehicle as it is being driven into position on the lift
and the load is resting squarely on the lift. Check the load limits of the
lift and adapter to make sure you don't overload them. Don't lock the hoist
controls in the open or shut position. They are to be operated manually. Make
sure the lift's mechanical locking device is working. You notice any irregular
operation or leaking oil, do not use the lift until you have determined the
cause and corrected it.

Hydraulic
Jacks

Hydraulic jacks are one
of the most useful tools in the shop. Before using a jack make sure it is
in safe, operable condition and that you are familiar with its operation.
Also, be sure the vehicle you are jacking is parked on a firm, level surface.
NEVER get under a vehicle supported only by a jack. To prevent a serious
accident, place wheel chocks around tires remaining in contact with the ground
before jacking. Always use jack stands under the vehicle with the hydraulic
jack. They'll keep the vehicle from falling on you if the jack is accidentally
released. As an added safety measure, also place heavy wood blocks (6"x6"
as a minimum) under axles or frame members as added protection should the
jack stands fail while you are under the vehicle. Check and recheck all safety
devices on hydraulic jacks. Don't exceed the weight limits posted on the jacks,
and keep it in good condition.

Racecarl says: "Bumper
jacks and Handy-Man jacks are widow-makers and should be regarded as such
at all times. NEVER even THINK about crawling under a vehicle
suspended by one of these."

Jack
Stands

If you are going to be
jacking your truck up and supporting it on stands, make sure you are working
on a firm, level surface capable of supporting several tons, and always use
stands with a minimum 2-ton capacity. Even then, consider where you live.
(ie California or anywhere along the San Andreas Fault Line.) It is always
best to work with jackstands, NOT the jack. When using jackstands, and getting
underneath the vehicle, if possible, place very large wooden blocks under
the axles, when axles are attached. Not a good idea to work with just jackstands
alone and no wheels and rims to catch the truck should it fall. When adding
the wooden blocks, a max clearance of an inch tolarance should be sufficiant.
This added safety measure should be about all you can do, short of chaining
the vehicle to the sky.

If you buy used jack stands,
make certain that you check the welds for cracks, observe any differences
in manufacture and give the the jack stands a thorough inspection -- It's
your life those things are designed to protect.

Anytime a jack stand is
used for the first time, be sure you read and follow the directions.

Carbon
Monoxide

Vehicle exhaust is a major
source of carbon monoxide, a deadly gas. Symptoms of overexposure to carbon
monoxide include a dull headache, dizziness, ringing in the ears, nausea and
pounding of the heart. To protect yourself and others from this deadly gas,
don't run vehicles in the shop. Only run vehicles in the shop if you have
a proper tailpipe exhaust system in operation.

Asbestos

There is very little exposure
to asbestos in most shops. However, if you repair brakes or work near these
operations, you could be exposed to asbestos dust. Breathing this material
could lead to asbestosis which is a disabling lung disease. Continued exposure
to asbestos may lead to lung cancer. Dust must be vacuumed from the drums
and floor with a special vacuum that has a high-efficiency particulate filter.
Dry sweeping, mopping or cleaning with pressurized air should be strictly
prohibited in your shop. Brake work requires personal protective equipment,
such as a filter respirator and safety glasses. When done, be sure to change
clothes if you have gotten any brake dust on yourself.

Flammable
Liquid Storage

Don't store or keep flammable
liquids in your work area. If possible, a seperate shed should be constructed
or purchased specifically for storing flammables such as gas cans, solvents,
thinners, paints, etc, and placed away from your living and working spaces
-- if practical. If your living space does not allow for the above. Always
dispose of gasoline at first chance as modern gas does not keep for very long.
If the gas is good, pour it into your car and burn it. If not, find out where
you can properly dispose of it. When storing your vehicle, drain the fuel
tank. Especially if the period is expected to be extended. (like a few years
during a major restoration). Nowadays, gas formulation does not allow the
liquid to store as well as in the past.

Solvents

You could be exposed to
solvents during parts cleaning, degreasing and spray painting. All organic
solvents have some effect on the central nervous system and skin. Inhaling
high concentrations of solvent vapors may cause a lack of coordination and
drowsiness or even damage to the blood, lungs, liver, kidneys and digestive
system. Skin contact may cause dermatitis, ranging from a simple irritation
to actual skin damage. Solvents can also dissolve the natural skin barriers
of fats and oils, leaving the skin unprotected. Solvents will be used in well-ventilated
areas only.

Appropriate personal protective
equipment including goggles, gloves, respirator and apron will be worn to
minimize exposure to solvents.

Spray
Painting

Spray painting can be a
serious health and fire hazard. Paint sprayed under pressure can be toxic
when inhaled. Thinning paint with solvents and then spraying it compounds
the problem by increasing the likelihood of combustion or even an explosion.
Prior to, during and after spray painting make sure the ventilation system
is working. Review the paint's Material Safety Data Sheet (MSDS) and container
label for hazards and safety precautions. Personal protective equipment must
be worn throughout the spray painting evolution. This includes safety goggles
and a properly fitted respiratory protection device. For a good fit check
the respirator for leaks each time you put it on. While spraying if you smell
vapors, stop painting immediately and check your equipment.

Epoxy
Plastics

Automotive body fillers
activated by chemical hardeners can cause rashes and sores if these hardeners
come in contact with your skin. If your skin comes in contact with any hardener,
wash it off immediately with soap and water. To prevent this kind of exposure,
wear gloves and a long sleeve shirt when working with epoxies.

Welding

While welding, goggles,
helmets and shields that give maximum eye protection for each welding and
cutting process must be worn, as well as gloves for burn protection. During
heavy work, flame-resistant material such as gauntlet gloves, aprons, and
leggings must be worn. Additionally, safety shoes must be worn when working
with heavy objects. Cotton clothing shall not be worn. Woolen clothing is
preferable because it is more resistant to ignition. Sleeves and collars must
be kept buttoned. Trousers cuffs will not be turned-up. Barriers should be
placed around the welding area not only for eye protection but also to minimize
vapors entering the shop area. Gas tanks shall be taken off vehicles, then
purged of flammable, combustible and explosive vapors. Keep your compressed
gas cylinders chained or latched so that they cannot fall over. Only move
them when they are attached to a cylinder dolly -- But turn those tanks off
when moving them, even just a few feet! .

Working
with a buddy

Working in the shop is
always more fun when you get to do it with a friend. Having someone else with
you also improves safety when you are working around or under dangerous machinery
(which just about everything in our shops qualifies as!) -- if something were
to happen, your buddy can either help you or call for more help. Having an
extra set of eyes and ears to watch or listen for unsafe situations can be
exceptionally helpful. When working with a friend, though, be sure you clearly
understand each other during your work. Sometimes, communication can impede
safety rather than improve it. For instance, make sure you use easily understood
words when working around machinery. Don't use words that sound similar but
could have terrible results if misunderstood, like NO! and GO!

Visitors
in the shop

All children and visitors
should be kept a safe distance from work area. A shop is an inherently dangerous
place for children, thus they should not be allowed in your shop area. Do
not allow children to play in your vehicle while you are working on it!
If there is a chance a child could gain entry to your shop, use padlocks,
master switches and remove starter keys and battery cables to childproof your
shop.

Insist upon safe work practices
for anyone visiting or working in your shop. You can be as safe as you want,
but it doesn't do any good if you have someone unsafe next to you. Their mistakes
can still involve you. Make sure those around you are safe too.